Manufacture of fiber sheets and apparatus therefor



- Aug. 1, 1933. D. M. SUTHE RLAND, JR 8 MANUFACTURE 9F FIBER SHEETS AND APPARATUS THEREFOR Filed April 8, 1951 4 Sheet-Sheet 1 -8 WITNESSES I 'LXNVENTOR #MJ DameZ/Wa/2$o/?Safbefliandfi,.

g- 1933. D. M. SUTHERLAND, JR 1 mmmcwuns 0F FIBER SHEETS AND APPARATUS THEREFOR Filed April 8, 1951 4 SheetsShee t 2 WITN ESSES- INVENTOR fi m fidiizlflfimsolz gainer/(1124,71; BY

Aug. 1, 1933.

D. M. SUTHERLAND, JR

MANUFACTURE OF FIBER SHEETS AND APPARATUS THEREFQ Filed April 8, 1931 4 Sheets-Sheet 3 T&

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ATT NE Y$ WITNESSES Aug. 1, 1933. D. M. SUTHERLAND, JR

MANUFACTURE OF FIBER SHEETS AND APPARATUS THEREFOR Filed April 8. 1931 4 Sheets-Sheet 4 INVENTOR. zszDamiwzzsozzy/uffieriaiza ig ATTORNEYS Patented Aug. 1, 1933 UNITED STATES MANUFACTURE OF FIBER SHEETS AND APPARATUS THEREFOR Daniel Manson Sutherland,

J r., Morrisville,

Lower Makefield Township, Bucks County, Pa.

Application April 8, 1931. Serial No. 528,478

7 Claims.

My invention relates to the manufacture of fiber sheets and the like, and to a wet machine for this purpose. By my invention, large sheets of any desired thickness and composition can be produced rapidly and economically, and of uniform good quality. Sheets so produced can be made into fiber board of any desired density and quality for which the materials employed are suitable. Furthermore, practically any additional material desired can be homogeneously distributed through the formed pulp sheet, and in the final board ultimately produced. Various advantages that can be realized through the'invention will be apparent to those skilled in the art from the following description.

In the drawings, Fig. I is a side view of a wet machine conveniently adapted for and cmbodying my present invention, with certain parts in vertical section as indicated by the line and arrows I-I in Fig. III.

Fig. 11 is an end view of the machine from the right of Figs. I and III, with certain parts in vertical section as indicated by the line and arrows II-II in Fig. III.

Fig. 111 is a plan view of the machine.

Fig. IV shows a vertical mid section through a portion of the mold and associated parts, illustrating the provisions for venting it and controlling the draining away of the water from the pulp.

Fig. V shows a horizontal section taken as in-' dicated by the line and arrows V-V in Fig. IV.

The wet machine here shown comprises a substantially horizontal mold in which aqueous fiber pi'lp is largely freed of its water and pressed into a compact, moist, frail sheet of interlaced fibers that can afterward be consolidated into coherent fiber board,-as by pressure and heat in a plate drier. The top and bottom mold walls 10 and 11 (Figs; I and II) are relatively movable, so that they can'be brought together to squeeze out the water, and provision is made for drawing or draining the .water away without allowing the fibers to escape. As here shown, the mold bottom 11 has a multitude of transverse drainage ducts or grooves 12 communicating with discharge headers 13 connected to suitable outlet or discharge means 14 (Figs. II and IV), controlled by any suitable means, such as that hereinafter described. Over the ducts 12 is a perforated or foraminous plate or screen 16 to retain the fibers of the pulp in the mold, while allowing the water to pass through into the ducts. The edge walls of the mold cavity are a formed by end and side deckels l7 and 18 shown in Figs. I and II as bolted together at 19 to form be closed, as shown in Fig. I, to shut oil? the mold a unitary frame around the top mold 10, which frame engages at its edges with the bottom edges of the deckels 17, 18 is pressed into the screen 20, making a reasonably tight joint. against the unperforated margins of the plate 16,and, of course, rendering the conveyor 20 immovable. When the deckel structure 17, 18 is raised and the mold opened for removal of the formed sheet, the conveyor 20 is freed from engagement with the deckel packing 21, and can be operatedto carry the sheet out of the mold, as hereinafter described.

Provision is made for introducing aqueous fiber pulp into the edge of the mold cavity and for allowing the air to escape from in front of the inflowing pulp, as hereinafter described. As here shown, hopper-like reservoirs 22, 22 are arranged to deliver directly into opposite edges (ends) of the mold cavity, through openings 23,

23 in the end deckels 17, 1'7. These hoppers 22 are shown in Figs. I and III as attached to the 5 end deckels 1'7 and. forming part of them. For the best results, it is important that the inlet openings 23, 23 extend substantially the full width of the mold cavity, as indicated in Fig. II; since if they be narrower, the rate of operation and output may have to be reduced to secure proper filling of the mold, and even then imperfect fiber sheets may be produced. Vertically sliding inlet gates 24, 24 (Figs. I and III) can cavity, when charged, from the supply reservoirs 22, 22, so that the pulp is then confined under the pressure exerted thereon,-save for the water drainage outlet through the ducts 12 and header 13 that is afforded as hereinafter described. The lower edges of the gates 24 make contact with the subjacent mold sills (forming part of the deckels 17, 1'?) on a bevel, so that the internal pressure in the mold is effectually resisted and. merely makes the joint tighter against leakage.

The reservoirs 22, 22 extend substantially the full width of the mold, and may be supplied with pulp by any suitable means, such as a system of piping 25 opening and dischargi into each reservoir hopper 22 through its cover 27. At the ends of each hopper 22 are pockets 28, 28 with return pipe connections 29, 29 back to the pulp supply source or tank, so that any excess of pulp delivered to the reservoirs 22, 22 may overflow and return to the supply. In the bottom of each hopper 22, at the side toward the mold, is a series of rotary paddles 30, for agitating and thoroughly mixing the pulp on its way to the mold outlet 23. These paddles 30 are mounted on a common shaft 31 extending into the pockets 28, and are driven by an electric motor 32 mounted on the mold cover 27, through connections including a chain and sprocket drive 33. Vertical webs 34 extend across the bottom of the hopper 22 adjacent the gate 24 between the paddles 30 and below the shaft 31. Their vertical edges lie directly behind and practically touching the gate 24, so as to sustain it against the internal pressure in the mold when the water is being squeezed out and the pulp compacted.

Provision may be made for venting the air from the mid region 'of the mold, from between the inflowing pulp streams, by any suitable means, such as the outlets 35 in Figs. II, IV, and

I V, further described hereinafter.

As shown in Fig. I, the pipe connections 26, 26 and 29, 29 to the pulp hoppers 22, 22 have sliding or slip-joints 38 to permit up and down movement of the hoppers with the deckel structure 17, 18.

In the present instance, the mold bottom 11 is stationary, consisting of a rigid casting resting on the foundations 39, while the mold top 10 and the deckel structures 17, 18 are vertically movable. Overlying the mold top 10, there is a rigid superstructure 40 on which are mounted.

the various parts and mechanisms for moving and controlling the mold top 10, the deckel structure 17, 18, the gates 24, 24, etc. This structure 40 is supported from the mold bottom 11 and connected thereto by four columns 41, two at either side of the mold. As shown in Fig. II, the lower ends of the columns 41 extend through marginal ears 42 on the bottom 11 and have shoulders at 43 that rest on these cars, and are securedby split nuts 44 threaded on the columns and locked by bolts 45. The structure 40 has marginal ears 46 through which the upper ends threaded and locked on the columns.

of the columns 41 extend; these ears 46 rest on split nuts 47 suitably adjusted and clamped on the columns, and'are secured by split nuts 48,

This construction not only allo s the superstructure 40 to be accurately adjustedand leveled relative to the mold bottom 11, by adjusting the collars 47 and 48, but also allows the machine to be easily taken apart when desired.

On the ends of the superstructure 40 are, mounted hydraulic motor or ram cylinders 50' whose plungers 51 carry yokes 52 from whose ends the-mold top 10 is suspended by link rods 53. By admitting fiuid under pressure to the cylinders 50, the mold top 10 is raised; by allowing the fluid to escape, it is lowered. To insure perfectly uniform up and down movement of the mold top 10, without tilting or cocking, equalizers are provided, consisting of pairs of rack bars 54 universally connected to the corners of the mold top and held in mesh with pairs of meshing pinions 55, 55 at opposite ends of the structure 40 by fixed guides 56, 56. The pinions 55, 55 are fast on the opposite ends of shafts 57, 57 extend- 10, to squeeze the water out of the pulp and com pact its interlaced fibers together, by means of four hydraulic motors or rams, consisting of limit the upward movement of the mold top 10,

adjustable stop screws 60, 60 are shown, one near each end of the mold top 10 at its center line, working in nuts 61 suitably fixed in the structure 40. These stop screws 60, 60 may be I operated in unison by means of a horizontal shaft 62, through worms 63 on said shaft meshing with worm gears 64 splined to the screw shafts60, 60 so as to turn the latter while at the same time permitting vertical movement of the screw shafts relative to the gears. The shaft 62 is shown with one end squared at 65 for operation by a hand crank (not shown), or by any other suitable means. By adjusting the stop screws 60, 60, the vertical depth of the mold cavity is adjusted, and thus the capacity of the mold and the thicknessof the pulp sheet produced may be controlled and varied as desired.

On the sides of the superstructure 40, just inside the columns 41, are mounted four hydraulic motor or ram cylinders 66 whose plungers carry yokes 67 to which the deckel structure 17, 18 is connected, by operating rods 68 extending down through the structure 40, with their lower ends secured to the side deckels 18, 18. By admitting fluid under pressure to the cylinders 66, the deckel structure 17, 18 is raised; while by allowing the fluid to escape, it is lowered. As shown in Figs. I and II, the side deckels 18, 18 havelateral guides 69 for engaging the columns 41,-shaped to conform to the column surfaces. Thus the deckel structure 17, 18 and the mold top 10 that slides within it are kept in proper relation to the mold bottom 11.

On the structure 40 is a hydraulic actuating motor for each of the gates 24, 24, comprising a cylinder 70 mounted on rods 71, 71 connected to yoke arms on the cylinder and to lugs 72, 72 on the structure 40. The plunger of each cylinder 70 has an operating rod connection to its gate 24,- whose upper portion 73 extends through a guide 74 on the adjacent cylinder 50, and whose lower portion 75 is hollow. Admission of fluid to the cylinders 70, 70 depresses and closes the gates 24, 24. The gates 24, 24 may be opened 12: by a common hydraulic motor 76 (of differential double acting type) mounted on the structure 40 and having on its plunger 77 a yoke head 78 connected by link rods 79, 79 to crank arms 80, 80 on a shaft 81 mounted in suitable bearings on the structure 40. On the ends of the shaft 81 are crank arms 82, 82 with link rod connections 83,

83 to the gates 24, 24, inside the hollow gate in bearings on brackets 87, projecting from the ends of the mold bottom 11, and the (right hand) roll 85 is driven by an electric motor 88 through gearing 89 (Fig. III). A spring-actuated friction brake device 90 may be connected to the shaft of roll 85 beyond thegearing 89, to control the conveyor belt 20 and prevent the motor 88 from racing when its load is suddenly reduced veyor screen is flattened in the mold, its ends are held open or expanded, as bypassing around the main rolls 85, 86 and beneath tensionand adjusting rolls 91, 92. Between the. mold ends and the rollsv 91, 92, the lower (return) of the conveyor 29 bends downwardaround guide rolls 93, 94, whose axes 95 are mounted in bearings on the brackets 87. Between the mold and the roll 85, the upper (activelrun of the conveyor brackets 97 areadj u'st able along ways on the brackets 87 by means of screws 98. v

The tension 1011,91 has its axes mounted links 99 'pivoted'onthe axes 95 of the adjacent guide roll 93.. Thus the roll 91 rests'andi-ffloats against the bight,or loop of the belt Z G'betw'een the rolls 85 and 9 3, exerting a pull that maintains a proper tension on the belt, while yielding to accommodate temperature changes, etc. The ad justing roll 92 has each of its axes mountedinj a bearing block 190 which is adjustable up 'or length of the conveyor belt 29 can be varied beyond the range taken care of by the tension roll device 99, 99.

Spray pipes 105, 195 maybe arranged-over the return run of the screen conveyor belt. 20, between rolls 85, 99 and "86, 91 in the belt-loops, for washing them ciean of adherent fibers-from the pulp, so that theftwo thicknesses .of screen shallalways aflord free passage for the water from the pulp through the foraminous plate 16 to the ducts .12. These spray pipes 105, 105 may be supplied Lwith wash water under pressure through a" pipe system 106. The spray strikes what has been the reverse or under side of the screen 20, so as to pass through and push ofi particles that have adhered-to the upper side in the mold.

As shown in Figs. 1, II and IV, the air outlet 35 leads to a cylindrical chamber 110 mounted on the deckel 18. This chamber 110 is ireely vented to the atmosphere through a grating 111 across its otherwise open top. The vertical diedge of a port '120 in the upstanding pipe'118.g

.mension of the outlet'35 where it opens through the deckel'18 is such as to cover the full range of verticaladjustments of the mold top 10, so as always to afford an air outlet from the upper region of the mold cavity. A barrier 112 affords an overfiowffor liquid from the outlet 35 at a height slightly above the highest adjusted position of the mold top 19, so that no pulp can escape through the outlet 35 until the mold cavity is completely filled. As here shown, the barrier 112 is defined by the lower edge of a port 113 in a drainage connection cylinder 114 extending up into the chamber 110. A packingllll'in the lower part ofthe chan'llzie'r. 110 assures tight joints. An opening .116 in the top of the cylinder" 114 allows free dischargeof air into the opentopped-chamber 110, and apipe 117 connected into the bottom of the cylinder afiords a discharge'for liquid (pulp'or water) to any con.- venient point.

As here shown, there is a curved pipe connection 14- from" the water discharge .ucts 1'2- and header 13,. leading downward and then up through the bottom of the cylinder 11 1, with an upright'extension 118 within the cylinder. From the pipe 118 there is a port 119 leading into the interior of the cylinder 11.4, defined by the lower connected to the. top inold z Thebottom edge pf t e,

level of thelowerside. of the. v Port 120 I and the" overflow at 1 119 are controlled by a valve sleeve 121 aroundthe' pipe 118, pro- 9 periorated plate 16.

, the-top of the, cylinder 30am} a flange 128 on the I val ve- 121, -to reinforce gravity; in depressing the 20. passes over a supporting roll 96,- whose bearing;

issust below the valve'; The valve lzlhas guide slots 129 for pins radon-the pipe 118, to insure proper correspond encetof the parts 120,-, 122.j- The upper ends of pipe 118 and valve sleeve 121. are open, to permit :Yfrce-vent ing of air,or even overfiow of liquid, incaseof need. As shown, there is a connection be summarized as follows: down in ways 101 by means of a screw- 102. By adjusting the roll 92 in this way, the effective Starting. with the conditions shown in Figs. I,

II, and IV, the water drainage port 119 is open.

ment, the mold top 10 overtravels the lower edge of the outlet 35, thus sealing off'the latter from the mold cavity. Then the deckels 17, 17, 18, 18 (with the associated parts) are raised, carrying the chamber and the gates 2 24 with them,--

,"without, however, causing the gates to open. The

cylinder 114, being fixed to the base 11, remains stationary. and'thus in efiect slides out of the chamber 110, virtually lowering the barrier 112 so that the pulp trapped in the outlet35 has a chance to overflow into the cylinderlid and escape through the pipe 117. The top mold 10 is raised to the position of Figs. I and II, and the fiber sheet is detached therefrom (if necessary) and allowed to drop back on the conveyor 20. The conveyor 29 is then operated to carry the fiber sheet (in either direction) out of the mold, for further treatment elsewhere.

The deckels 17, 17, 18, 18 (and the associated parts) are now lowered again to their positions in Fig. I. The hoppers 22, 22 having been filled with pulp from the piping system'26, the gates pulpenters the outlet 35, and may evenoverfiow.

at 112 into the lower end of the cylinder 114. The

gates 24, 24 are c1osed,-bringing the apparatus back to the condition of Figs. I and II, ready for another cycle of operation.

Having thus described my invention, 1 claim:

1. A method of charging with aqueous pulp a horizontal mold for forming pulp sheets bypressing and drawing off the water from the pulpin the mold; which method comprises admitting the pulp into the mold at opposite edges and concurrently allowing the air in the mold to escape from its mid region, separately from the water of the pulp.

2. A method of charging with aqueous pulp a horizontal mold for forming pulp sheets by pressing and drawing off the water from the pulp in the mold; which method comprises admitting the pulp into the mold through an edge opening extending substantially the full width of the mold, concurrently allowing the air to escape from in front of the inflowing pulp, while preventing escape of the water from the pulp until after the mold is fully charged. I

3. A wet machine of the character described for forming pulp sheets, comprising a horizontal mold with relatively movable top and bottom walls, means for introducing aqueous pulp into the mold at opposite edges and for venting air from between the infiowing pulp streams, while preventing escape of water from the pulp until after the mold is fully charged, and means for thereafter drawing away the water from the pulp in the mold.

4. A wet machine of the character described for forming pulp sheets, comprising a horizontal mold with relatively movable top and bottom walls, means for introducing aqueous pulp into the mold at opposite edges and for venting air from between the infiowing pulp streams, and means for separately drawing away the water from the pulp in the mold.

5. A wet machine of the character described for forming pulp sheets, comprising a horizontal mold with relatively movable top and bottom walls comprising means for introducing aqueous pulp, pulp supply reservoirs at opposite ends of the mold having a combined capacity sufficient to fill the mold and opening directly thereinto through openings extending substantially the full width of the mold, with gates for said openings, means for venting air from they mid-region of the mold, and means for separately drawing-away the water from the pulp in the mold.

6. A wet machine of the character described for forming pulp sheets, comprising a horizontal mold with relatively movable top and bottom walls, means for introducing aqueous pulp comprising pulp supply reservoirs at opposite ends of the mold having a combined capacity sufiicient to fill the mold and opening directly thereinto through openings extending substantially the full .width of the mold, with gates for said openings', means for agitating the pulp in said reservoirs, means for venting air from the mid-region of the mold, and means for separately drawing away the water from the pulp in the mold.

7. A wet machine of the character described for forming pulp sheets, comprising a horizontal mold with edge deekels and top and bottom walls; means for raising and lowering one of said walls; means for preventing unequal action of said raising and lowering means on different portions of said wall, and thus causing uniform rectilinear movement of said wall, without cocking; means for positively limiting the separation of said walls, adjustable to vary the mold capacity; and means for raising and lowering said deckels.

DANIEL MANSON SUTHERLAND, JR. 

